Electric heating device.



W. STANLEY. ELECTRIC HEATING DEVICE.

APPLIOATIO! FILED IA! 13, 1909.

Patented Dec. 10, 1912.

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ATT4Y;

w. STANLEY.

ELECTRIC HEATING DEVICE. APPLIOATIOH FILED IA Y 13, 1909.

Patented Dec. 1 0, 1912. Y

5 SHEETS-SHEET 2.

, INVENTUR. WiLLiAM TANLEY Wiwuczscz:

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W. STANLEY.

ELECTRIC HEATING DEVICE.

APPLICATION FILED MAY 13, 1909.

Patented Dec. 10, 1912.

6 8HEETS-SHEET 3.

INVENTEIR:

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WiLLiAMfiTANLEY ATTY? W. STANLEY. ELECTRIC HEATING DEVICE.

APPLICATION FILED MAY 13, 1909. 1,046,881 Y Patented Dec. 10, 1912.

6 8HEBT'8-BHEET 4.

x iiia! m I llllmml llllml" WiTNEfijEjI INVENTU WiLLIAMB-FANLEY W. STANLEY. ELECTRIC HEATING DEVICE. APPLICATION FILED MAY 1 3, 1909. 1,046,887.. Patented Dec. 10,1912.

6 SHEETS-SHEET 6. Fig. )6.

IN YENTUR I/YILLIAM STAZSZLEK BY Mw Flll.

WITNESSES mxfim ATTK PATENT WILLIAM STANLEY, or GREAT BARRINGTON, MASSACHUSETTS,

assrenon To GENERAL ELECTRIC COMPANY, A CORPORATION OF NEW YORK.

ELECTRIC HEATING DEVICE.

making electrlc heaters to fasten the heating element, usually a resistance wire wound or refiexed, on the outside. of the heating device by clamping upon an intervening layer of insulation, or causing it to adhere to a layer of enamel.v I proceed in a radically different manner by inclosing the heating elementin a close fitti of steel, or other suitable heat conductor; thin insulation of mica or other non-conductor being interposed between the walls of the casing and the heating element. The a1' mored heating element thus produced is placed in a mold properly prepared by a pattern, and molten aluminium, iron, or other metal is poured into the mold to produce a casting of the propershape of the utensil desired with the heating element embedded otherfinsulation, holding it stably underwithin the body of the casting properly insulated. The heating device thus produced may be a stove, pan, pot, flat iron, or any electrically heated appliance desired. A The product is one in which the heating element isclad in a durable protective armor msuring the device against damage by abuse, and what is more important still, insuring an intimacy of contact between the heating ele ment and the heat distributing body, which can be secured in no other way. The shrinkage of the cast envelop produces an enormous pressure and compacts the mica or molecular pressure, and thereby increasing. 'its thermal conductivity: the shrinkage further effects a maximum thermal conductivity between the heating element and the double metal armor which incloses it. In this,

.way not only is all the heat generated by the watt energy consumed in the heating element rendered available for work in the domestic or other. operation carried on and the Specification of Letters Patent.

finite period. A wire of this kind is' the g refractory casing practically maximum economy thereby insured, but the. thermal drop between the source, and the work is greatly reduced, and the tempera- Patented Dec. 10, .1912. Application filed May 13, 1909. Serial No. 495,733. v

ture of apart of the device where heat is to beapplied to useful work is raised quickly. I prefer to employ for the heating element a wire or ribbon made of a refractory metal, which will stand hard service without deterioration or disintegration for an indefichrome-nickel alloy covered by the patent of Dempster, No." 901,428, dated October 20,

v 1908. Other kinds of such wire might, how- -ever, be employed, the prime consideration being ability to successfully stand service temperatures of the heating element for a long period. I prefer the chrome-nickel alloy, however, as it has a very high melting point and a very high specific resistance and, therefore, might be run safely at even a red heat. By reason, moreover, of its high specific resistance the wire may be made of larger cross section and stronger than is possible with materials of alowerspecific resistance; but with any kind of selected wire the durability of the cast-in unit of my invention is limited only by the durability of the device itself. The heating elebeing sealed in its metallic armor, is as safe as if inclosed-in a vacuum, and is, therefore, guarded against thedeteriorating influence of the atmosphere, or

ment

other causes which might tend to change-its stability. l

Having thus outlinedin a general way the nature of my invention, I will now more particularly set forth the best manner I' have thus far developed for carrying it into effect. Y

A ribbon of resistance wire is wound on.- a thin sheet mica support, or a punched grid or reflexed ribbon without any support is laid between two thin sheets of mica a few mills in thickness, and placed in a sheet-iron or mild-steel casing. A thin sheet of iron or steel is then laid on top of the upper sheet of iniea, and the under sheet is closed over by folding, crimping, peening, pressing, weldingor brazing,or by any improved method of making a compact closure which will keep the heating element firmly bound within it. 1 Fins-or spurs at several symmetrical points, I

allowed to project, and these form prints or points of support for the. in'cased unit inthe' integral with the casing, are

mold: A sand mold is made from a pattern of the desired utensil, and the incased heating unit above described is laid in the bottom or other appropriate part; the lead wires for the resistance element being carried out of the same through the prints. Molten metal is then poured into the mold. This may be aluminumpbrass, copper, iron, or any metal desired, having a lower melting point than, the casing around the heating element. The device, when removed from the mold, has" the heating element her met-ically inclosed in a substantial metal at"- mor,'and the latter may be tooled or finished where necessary by ordinary methods, and 'the heating element leads connected with terminals in a block of insulation to complete the device for the market. In the 'case of a saucepan, frying pan, kettle, or

the like, in which the work is above the heater, I make the casting with the incased heating element in the bottom; the latter covering the desired and almost entire area of the bottom of the utensil. To effect this a size of ribbon is selected to produce the required drop of potential when .the desired area is covered, .or in case a punched grid is employed, the punching die is shaped to form parts of the grid ofproper sectional area. Inthe case of a flat iron,,-where some part, as the toe of theiron, might preferably have a higher heat, I mount the incased heatin element in an inclined position in the 111011 whereby a smaller mass of metal intervenes between the toe of the iron and the heating element, so that a higher temperature will be maintainedat this-point, because the path of thermal resistance is shorter, and besides,

the temperature of this part will be more easily maintained when damp goods, or similar exacting work rapidly extracts the -heat of the iron. By my mode of procedure not only does the molecular shrinkagz of the casting contribute by its great pre:su.re in establishing good heat joints between the resistance element and the insulation, but by a proper selection of the materials of the element casing and the casting metal the surface portion of the casing'will fuse slightly so as to unite the casing with the casting metal. Further than this an important result follows the use of the metal casing between the cast armor and the insulated resistance element, the latter being free to move or slip somewhat when thelcasting operation takes l place, it is not broken by shrinkage of the ca sting nor canthe insulator be cracked from this cause and produce a short-circuit. It will thus be seen that my-invention comprises a suitable casing for a suitable heat element completely inclosing and insulating it, and a cast metal armor to distribute the heat; it comprises 'also the new process ofmanufacture described. Theseveral specific features of the envelop Wlll be set forth more at length out in the claims.

hereinafter, and win be particularly pointed Referring now to the drawings, Figure 1 shows a side elevation, partly in section, of a fiat iron embodying my invention, the inclined heating element being shown in dotted lines; Figs. 2 and 3 isometric projections of the two parts of the metal casing. in which the heating element for the flat iron is inclosed; Fig. 4: is a plan View of a punched iron grid shown in the bottom portion of its casing; Fig. 5 is an isometric projection of the completely incased heating element for a flat iron ready for application to the mold; Fig. 6 is a sectional view across the toe of the heating element, the parts being very much exaggerated in size to show them more clearly; Fig. 7 is a plan view, showing the flat iron in its mold, the upper part of the mold being removed, and the body of the casting shown in section; 8 is a side elevation of the met-a1 casting of the sole, or lower part of the flat iron containing the heating element cast in, the latter being shown in dotted lines; Fig. 9 is an isometric pro ection of an inca'sed heating element, showing another method of crimping the parts of the .casing together; Fig. 10 is a sectional View of F ig. 9, showing arrangement of the heating element in its casing, the parts being very much exaggerated in size to show them more clearly; Fig. 11 is an isometric projection of a casing for the heating element, the parts of which are welded or brazed together; Fig. 12 is a sectional View of Fig. 11, the parts being very much exaggerated in size to show them more clearly; Figs. 13 and 14 are isometric pro= jections of parts of a round casing for the heating element; Fig. 15 shows a completed saucepan with the heating element cast in;

Figs. 16 and 17 show another form of heat-' ing element, in which the resistance ribbon is wound on a mica ring and inclosed between mica rings incased in metal, and Fig. 18 is an enlarged detail of the design of Figs. 16 and 17. It will be understood from these drawings that the specific embodiments shown,

namely, a fiat iron, saucepan and pot, are

merely samples of applications of the invention, and that it may be applied in any type of electric heater.

Referring now to the flat iron shown in F igs-1 to 12 .of the drawings, 1 represents the sole piece of ti e iron and Qthe cap, the former containing the cast-in incased heating element 3; the two parts being separated by heat insulation, as asbestos, indicated at 4, and fastened together and to the handle by means of screws 5, 5, 6. The upper casting may be provided with a hood 7, under which the terminal connections of the heating element are made with metallic pins 8 adapted to-form a connection with'a flexible cord or plug leading to a suitable source of electric supply in the manner usual 1n the .art. Theheatingelement 3 consists of'a re sistance, grid or ribbon. A punched grid, which I sometimes employ, is seen in Fig. 4, where a sheet of high resistance metal of the alloy hereinbefo-re mentioned, or other resistance medium ispunched, out or sheared, so as to provide a tortuous path for the current and of an outline of the fiat iron, the central partbeing open to permit the heat to' be evolved principally along the working surfaces'ofthe iron and to effect uniform distribution as the heat does not so readily diffuse from the inner parts. Integral with the grid are terminals 9, 9 forked to span a screw. This heating element is laid in a pressed cup, as F ig. 8 or 4, of sheet iron or mild steel, the cup being provided with openings at 10 10", 10, which serve as prints to support the element inthe mold and to permit the terminals to be'carried out, as will be evident from Figs. 4 and 5. A thin sheet of mica is laid in the bottom of the clip 10; the resistance element is laid above it; anothersheet of mica is placed on top of the resistance element, and a thin sheet of iron (as shown in Fig. 2, at 11), conformingin shape to the cup, is laid above the upper sheet ofmica. The vertical ridge 12 (Fig. 3). of the cup is then closed over in 'a press,

producing a wide flange, as indicated in Fig. i

5, which givesa practically airtight seal to the insulated resistance element in the iron casing. The terminals'projeet as indicated in Fig. 5. The incased resistance element thus produced is laid in a sand mold, whichhas been previously prepared with a pattern conforming to the sole of the flat iron 1. Metal is then poured in the mold and completely incases the iron-clad resistance element, .the mass of iron connecting the upper and lower portions through the 1101- low central space v12, the terminals being protected by a chaplet, as indicated in Fig. 7 and-the prints being supported as indicated in dotted lines. When the casting is removed from the mold the heating element 3 is incased therein,as indicated in Figs. 1

)and 8,and the projecting prints are dressed toe, which is desira off. Iprefer to support the heatin element in an inclined position in the mol so that the part adjacent to the toe of the iron iscloser to the sole than-the main body thereof. In this way greaterihe is evolved the In Figsr9 and 10a i ing is shown,-in 'whichthe verticalrib'of the casing is notched and thefgjwings 13- are peened 'or folded over on the top plate.

The dimensions are very much exaggerated in f'all of these figures, as the completedheating element is formed of sheet iron about 84 mills in'thiclmess, the resistance element itself being only a few mills in thickness, and the mica also a few mills in thickness.

In Figs. 11 and 12, is shown aform in I which the parts of the casing are'j si-mplypunched sheets of metal laid on the top and bottom of the insulated resistance element,

'escape into. the molten metal and cause a defective casting. The sheathing being formed of wrought iron, has a higher melting pointthan the cast iron, and may be 5110- cessfully inclosed in the casting which will slightly fuse the same without injuriously affecting it. In cooling the large massof cast iron shrinks, producing an enormous molecular pressure upon every part of'the resistance element, compacting the mica into' a minimum space and. forcing with tremendous pressure all of the parts into the best possible relation for good thermal conductivity. From this it results that'the heat disengaged by the heating element flows with maximum freedom across the mica insulation to the working face of the iron, and there is a minimum lag in heat transmission between the heating element and the work. In the design shown in Figs. 13,.and 14 and 15 the heating units are applied to an open vessel, such as a saucepan. For culinaryutensils for boiling or heating. liquids the inclcsing casting may with advantage be made of a-metal of lower melting point. I have found aluminum very satisfactory both from a manufacturing and commercial standpoint. The method of manufacture is essentially the same as that hereinbefore described, except that in this case a larger heat area is to be covered, and I prefer to employa double heating element by forming two iron-clad resistance elements concentrically arranged, as indicated at 14, .15 in Fig. 15,

the terminals being brought out through three iron cups 16, 16, 16 of Fig. 14, these cups being attached to the bottom section'of the casing. In this case a double annular rib 17 is formed in the lower section of the easing, and after the 'parts of the unit are as' sembled the plate 18 is laid on top of the casing and the vertical ridge closed over in a press, so as to seal and inclose the insulated heating element. 'Prints 19,19, etcL, jsynnnetrically arranged, areriveted to the casing for proper assembly infi' the mold, as

' herei'nbeforedescribed, the only difference being that the pattern is varied to form a. sauce pan, or other open vessel in a manner. well understood by those familiar withcasting metals. The terminals are carried out through the openings 16, 16, 16 suitably lined-with insulation, as indicated at19fin Fig. 15, and a plug of, refractory insulating compound'is'secured by 1 g screws 20 engaging a threaded iron socket made apart of the casting, as indicated at 21. If desired, rivets, as 22, may be formed in the casting, by which feet may be attached to the pan.

In Figs. 16, 17 and 18 the unit is formed by winding a thin ribbon of high resistance metal on .a ring 23 of mica, similar mica rings being placed on the top and bottom,

- on the inside and outside and sheet iron or steel rings 2 1 (Fig. 18)

superposed at top and bottom. The joints may be formed by placing iron rings 25, 26

of the heating element and brazing or welding along the inner and outer-peripheral edge. Terminals may be brought out, as indicated at 27, 28', and the incased unit cast in a manner similar to that hereinbefore described. A plug of refractory insulating compound 29, having a terminal 30 aifixed thereto, may be connected with the terminal to fit the device .for service.

' sistance conductor formed to cover an area conforming to the shape of the body to be heated, a similarly formedmetallic casing inclosing said conductor, and a body of metal cast around the casing.

2. An electric heater, comprising a resistance element having an insulating medium and an inclosing metal shell around it, and a casting of'meta'l having a lower melting point than the shell inclosing all.

3. An electric heater having a cast-in ini to promote heat distribution.

sulated heating element tilted in the casting to vary'the heat distribution.

4:. An electric heater, comprising a resistance element insulated in an inclosing inc-- tallic casing, a casting around the whole enveloping it Without joints, terminal connections with the element, and cast-in lugs for attaching accessory parts.

5. An electric heater, comprising a resistance element inclos'edin and insulated from a two-part metal casing with airtight joints, and a casting inclosing the whole in a solid armor. I p

6. An electric heater, comprising a resistance element, insulation around the same, a casing around the insulation, anda casting' enveloping the casing, said casting threading the element at an interior point 7 An electric heater, comprising a resistance element having an interior opening,

a metalliccasing about the same having a corresponding opening, and a casting inclosing both in a metallic envelop covering the inside and outside of the opening.

8. A flat iron having a sole casting containing an inclosed insulatedresistance element cast within the same, a heat insulated cover on the sole, and a handle attached to the flat iron.

v9. The process of making an electric heater, or the like, consisting in insulating and inclosing the resistance element in a metal shell, supporting the shell in a hollow mold with the element terminals protected, and then casting around it a metal having a melting point such that it will slightly fuse the surface of the shell.

In witness whereof, I have hereunto set my hand this 6th day of May, 1909.

' WILLIAM STANLEY.

Witnesses:

ENSIGN WORTHY, P. A. SMITH. 

